Active front deflector

ABSTRACT

An active front deflector assembly having a deflector panel, actuator, and linkage assemblies each with a predetermined geometry and ratio of links to each other for movement of the active front deflector assembly between at least a deployed position and a retracted position. The deflector panel is positionable at multiple heights. The assembly deploys and retracts based on vehicle requirements, and, when deployed, redirects the air flow in the front of the vehicle to improve the vehicle aerodynamics for either fuel economy or performance characteristics. Additionally, it allows for the deflector panel to retract so the vehicle meets ground clearances, etc. The deflector panel is also both rigid and semi-rigid to absorb impact energy. A drive shaft transmits the drive from one side to the other side. The deflector is both rigid and semi rigid to absorb impact energy.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/928,853, filed Mar. 22, 2018, which is a continuation of U.S. patentapplication Ser. No. 15/318,233, filed Dec. 12, 2016, issued as U.S.Pat. No. 9,956,998, which is a National Stage of InternationalApplication No. PCT/US2015/035127, filed Jun. 10, 2015, which claims thebenefit of U.S. Provisional Patent Application No. 62/010,854, filedJun. 11, 2014. The disclosures of the above applications areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a panel structure of an active frontdeflector system for automotive applications.

BACKGROUND OF THE INVENTION

There is a considerable loss of aerodynamic efficiency in vehicles, inparticular, due to the airflow underneath and around a vehicle.Conventional structures, such as fixed panels or fixed airdeflectors/dams using flexible materials, are known and do not meetdesired requirements. These fixed air deflector/dams are still acompromise as they cannot be made to the optimum height withoutcomprimising specifications and comparisions to other vehiclecapabilites. Further, these air dams even when flexible are stilldamaged during off-roading or when added ground clearance is needed.They also do not have the capability of being placed at multiplepositions.

Accordingly, there is a desire for an active front deflector thatprovides an aerodynamic surface for improved aerodynamic when deployed,but is retractable out of the way under predetermined conditions toreturn the vehicle to its initial design intent, and which is alsocapable of reaching multiple positions.

SUMMARY OF THE INVENTION

There is provided an aerodynamic surface which improves aerodynamicswhen deployed and is retractable out of the way to return the vehicle toits initial design intent, as well as capability of reaching multiplepositions depending on the application and different driving situations.The present invention is directed to an active front deflector assemblyhaving a deflector panel that is movable by an actuator attached to alinkage arrangement. The retractable deflector located in the front ofthe vehicle under the body is capable of changing the vehicleaerodynamics. The deflector redirects the air flow in the front of thevehicle to improve the vehicles aerodynamics for either fuel economy orperformance characteristics. The deflector is held in place by two fourbar linkages with a specific arrangement and ratio of the links to eachother critical to the motion of the deflector.

The active front deflector assembly is retractable so that it does notcompromise the vehicle capabilities for conditions such as when addedground clearance is needed, and is deployable for normal drivingconditions. When in the extended or deployed position underpredetermined conditions, the deflector panel improves airflow. When inthe retracted or stowed position, the deflector panel rises out of theair flow.

The active front deflector assembly is held in place by at least twofour bar linkage arrangements with specific geometry/ratios of links toone another that are critical to the desired motion of the deflectorpanel, and will allow them to reach multiple positions for differentpredetermined driving situations. The deflector panel can be positionedat multiple heights In addition, a drive shaft transmits the drive forcefrom the left side to the right side or vice versa, of the linkagearrangement. The deflector panel is both rigid and semi-rigid to absorbimpact energy.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a front perspective view a vehicle with an active frontdeflector assembly in a deployed position, in accordance with thepresent invention;

FIG. 2, is a perspective view of an active front deflector assembly in adeployed position, in accordance with the present invention;

FIG. 3, is an enlarged rear perspective view depicting a linkageassembly of the active front deflector assembly of FIG. 2, in accordancewith the present invention;

FIG. 4, is an enlarged side elevation view of the deployed active frontdeflector assembly of FIG. 2, in accordance with the present invention;and

FIG. 5, is an enlarged side elevation view of the active front deflectorassembly of FIG. 2 shown in a retracted position, in accordance with thepresent invention, and

FIG. 6, is a schematic of linkage ratios and geometry of the linkageassemblies of the active front deflector assembly in a deployed positionand a retracted position, in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to FIGS. 1-6 generally, in accordance with the presentinvention, there is provided an active front deflector assemblygenerally shown at 10, moveable between at least a stowed position (or“retracted” position) and deployed position (or “extended” position)and/or at least one intermediate position, under predeterminedconditions. The active front deflector assembly provides an active fullair deflector that deploys and retracts based on predetermined vehiclerequirements. This allows for a deployment lower than fixed panelsystems to significantly reduce drag, reduce emissions, improves fueleconomy, (and/or improve active grille shutter performance when used incombination with the active front deflector assembly). Additionally, itallows for the system to retract so the vehicle can still meet groundclearances, ramp angles, off-road requirements, etc. These aresignificant improvements over typical vehicle systems utilizing a fixedsacrificial panel below and/or near the fascia to achieve basic and lesseffective aerodynamic improvements.

FIG. 1 is a perspective view of an active front deflector assembly 100shown in an environment of use attached to a vehicle 16, in accordancewith the present invention. This is typical of the environment and showsthe active front deflector assembly 100 in the deployed position, inaccordance with the present invention.

Referring to FIGS. 2-6 generally, in accordance with another embodimentof the present invention there is provided an active front deflectorassembly generally shown at 10 movable between at least a stowedposition and a deployed position under predetermined conditions. Theactive front deflector assembly 10 generally includes at least onedeflector panel 1 that is semi-rigid with a rigid upper spine 2 portion.Most preferably, the semi-rigid and rigid portion are integrally formed.The deflector panel 1 is coupled to at least two linkage assembliesgenerally shown at 12, 14 that are four bar linkages. The two four barlinkage assemblies 12, 14 are operable spaced apart to provide strength,durability, and installation on the vehicle, while preventing bindingand allowing smooth transitioning between the deployed and retractedpositions.

Each linkage assembly 12, 14 has a drive link 3 and a follower link 4pivotally connected to a coupler link 5 and pivotally connected to afixed base link 6, respectively. The coupler link 5 also includes amounting portion 18; e.g., an integrally formed mounting bracket withapertures 20 for receiving fasteners 22, to operably couple each of therespective linkage assemblies 12, 14 to the rigid spine 2 of thedeflector panel 1. In this embodiment, there are two linkage assemblies12, 14 used with each active front deflector assembly 10. However, it iswithin the scope of the invention that more or less linkage assemblies12, 14 may be used, depending upon the length of the assembly 10 andparticular application.

At least one fastener 22 (FIG. 3) is used to connect each of themounting portions 18 to the rigid portion 2 of the deflector panel 1. Atleast one pair of sloped webs or fins 36 extend from the coupler link 5main body 38 and are affixed to, or integrally formed with, the mountingportion 18. e.g., generally L-shaped mounting portion 18 with upperportion 40 attached along the top of the upper spine 2 and lower portion42 located along the front side of the upper spine 2.

The assembly 10 is operably supported and connected to a fascia portionof the vehicle 16, bumper reinforcement, fenders, frame or any othervehicle structure or molding for securing the linkages of the assembly10 to the vehicle 16. The assembly 10 is attached to the underside ofthe vehicle 16 towards the front with at least two attachment brackets24 connected to or most preferably, integrally formed with the fixedbase link 6 of each linkage assembly 12, 14. Each of the linkageassemblies 12, 14 is then attached to the vehicle 16 by at least onefastener 26. Each fastener 26, preferably, at least three, extendsthrough a corresponding one of at least one aperture 28 formed as partof attachment brackets 24. All of the fasteners in this embodiment arenut and bolt combinations, but it is within the scope of the inventionthat other fasteners, such as rivets, may be used as well.

The coupler link 5 includes at least two pairs of apertures throughwhich two additional fasteners 30 extend, respectively, and eachrespective fastener 30 also extends through a corresponding end of thedrive link 3 and follower link 4. e.g., through a cylindrical-shapedopening formed in the links 3, 4, thereby pivotably connecting the drivelink 3 and follower link 4 to the coupler link 5. The fixed base link 6also has at least one pair of apertures through which an additionalfastener extends, which fastener 30 also extends through a correspondingend of the follower link 4, thereby pivotably connecting the followerlink 4 to the fixed base link 6.

The coupler link 5, drive link 3, follower link 4, and fixed base link 6of the two four bar linkage assemblies 12, 14 have predeterminedgeometry and ratio of links to each other critical to the motion of thedeflector panel 1 between at least the deployed and retracted position.

In the deployed position, each of the linkage assemblies 12, 14 form aparallelogram shape, preferably, where both pairs of opposing sides(e.g., first pair “x,x” and second pair “y,y” in FIG. 6) are equal inlength and parallel, respectively, and, most preferably, additionallywhere none of the inside corner angles is 90°. The angle between thefixed base link 6 and drive link 3 in the deployed position is 76degrees, the linkage assembly 12 and 14 are each a parallelogram, thedrive link 3 and follower link 4 are the same length, and the couplerlink 5 and fixed base link 6 are the same length as each other. Thelength of the coupler link 5 and fixed base link 6 is less than thedrive link 3 and follower link 4. The angle between the fixed base link6 and follower link 4 in the deployed position is 104 degrees. In theretracted position, the angle between the fixed base link 6 and followerlink 4 is 66 degrees.

The active front deflector assembly 10 is attached to the underside ofthe vehicle towards the front, e.g., using the at least two attachmentbrackets 24 provided on the fixed base link 6 and fasteners 26. In thedeployed position (generally down) the deflector panel 1 is in the airflow (see FIGS. 3-4); the rigid part 2 is not in the air flow and isprotected by the vehicle body 9. The deflector panel 1 interrupts theair flow thereby improving the vehicle aerodynamics. However, thisdeployed positioning reduces the vehicle ground clearance. When thevehicle needs its full ground clearance capabilities the deflector panel1 is retracted (generally up) (e.g., see FIG. 5).

At least the drive link 3 and follower link 4 each have strengtheningfeatures, e.g., such as generally a U-shape or channel shaped and/orother suitable structure to add strength while minimizing weight,generally along its length from one joint area to the other joint areaof the links. The deflector panel 1 preferably has trusses 42 betweenintermittent vertical walls and/or other suitable structure to addstrength while minimizing weight.

One of the linkage assemblies 12, 14 e.g., the left hand four barlinkage 12, also has an actuator 32. The linkage assemblies 12, 14 areconnected to the deflector panel 1, 2 and to a drive shaft 34 which iscoupled to the actuator 32. The linkage assemblies 12, 14 are joined bythe deflector 1, 2 (via coupler link 5 of both linkages 12, 14) and thedrive shaft 34. Retraction and deployment of the active front deflectorassembly 10 is achieved by the actuator 32.

The actuator 32 is attached to the drive shaft 34 which is attachedtoward the ends of the drive links 3 of both linkage assemblies 12, 14.The drive shaft 34 also extends through apertures formed in both fixedbase links 6 adjacent to corresponding ends of the drive links 3. Inoperation the actuator 32 rotates the drive shaft 34 which rotates thedrive links 3 upward, folding the follower links 4 and coupler links 5up and causing the deflector panel 1 to rise out of the air flow (FIG.5) to the retracted position. This motion is achieved with the geometryof the bar linkage assemblies 12, 14 and the ratio of the links to eachother (e.g., FIG. 6). For this particular geometry, the motion of thedeflector panel 1 is largely vertical which allows for deploymentpositions in between the end points for use in specific drivingconditions.

The actuator 32 rotates the drive shaft 34 in the opposite direction torotate the drive links 3 downward, causing the follower links 4 andcoupler links 5 down and causing the deflector panel 1 to lower into theair flow (e.g., FIG. 4) to the deployed position.

The linkage assemblies 12, 14 and the ratio of the links to each otheris critical to the motion of the deflector panel 1 and has significantadvantages over conventional systems. The deflector panel 1 can bepositioned at multiple heights, which is yet another significantadvantage over typical systems. The drive shaft 34 also transmits thedrive from the left side to the right side, or vice versa. The deflector1,2 is both rigid and semi-rigid to absorb impact energy, which isanother significant advantage.

The actuator 32 is selected from the group consisting of a rotaryactuator e.g., with feedback options, hex-type, screw-type drive, higherspeed actuator, electric, mechanical linear, e.g., with current overridecircuits, declutching hydraulic, pneumatic, extending, power liftactuator, or any other actuator and combinations thereof depending onthe application and predetermined vehicle needs. Depending on theapplication, the actuator 32 is not a clutched actuator

Suitable electontronics, preferably a shut off printed circuit board(PCB) with connector contacts correlate with vehicle communicationnetworks for commanding a motor based upon predetermined conditions,e.g., commanding energizing of the motor correlating with predeterminedvehicle speed ranges. By way of non-limiting example, the deflectorpanel 1 is retracted until the vehicle reaches a predetermined speed of30 miles per hour, then the deflector panel 1 is extended and staysdeployed until the vehicle drops back down to below the predeterminedspeed, e.g., 30 mph, or other predetermined conditions for continueddeployment are no longer met. The actuator 32 has communicationcapability with the vehicle 16. The actuator 32 and the vehicle 16 alsocommunicate to deploy and retract the deflector panel 1 based uponpredetermined conditions such as vehicle speed, wind direction yaw, etc,and combinations thereof. By way of non-limiting example, the deflectorpanel 1 is retracted until the vehicle reaches a predetermined speed of30 miles per hour then the deflector panel 1 is extended and staysdeployed until the vehicle drops back down to below the predeterminedspeed, e.g., 30 mph, or other predetermined conditions for continueddeployment are no longer met.

When the deflector panel 1 is down in the deployed position it isextended generally about one quarter to one half of the distance to thetraversed ground surface, preferably, about one third of the distance.Depending on the application, the deflector panel 1 is selectivelypositioned at a plurality of predetermined heights.

The deflector panel 1 is made of a composite plastic in this particularembodiment. However, it is also within the scope of the invention tomanufacture the deflector panel 1 of different materials such as steelor aluminum (depending on the particular application), painted carbonfiber, extruded rubber, or other suitable impact resistant material towithstand a predetermined load without departing from the scope of theinvention. Additionally, the deflector panel 1 may consist of a singlepiece, e.g., of molded composite plastic, or multiple pieces assembledor molded together.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. An active front deflector assembly for a vehicle,comprising: at least one deflector panel, where the deflector panelselectively deploys and retracts between at least a deployed positionand a stowed position, where the deployment of the deflector panelimproves aerodynamics; at least two linkage assemblies attached to thedeflector panel and adapted to attach to the vehicle, each linkageassembly forming a parallelogram of links when in the deployed position,wherein one of the links includes a mounting portion that is L-shapedwith an upper portion attached to a top surface of the deflector panel;a drive shaft operably coupled to the at least two linkage assemblieswherein the drive shaft transmits the drive from one side of the activefront deflector assembly to the other; and an actuator operably coupledto the linkage assemblies and drive shaft, where the actuator is incommunication with the vehicle and deploys and retracts the deflectorpanel under predetermined conditions; wherein the parallelogram geometryand a ratio of the links to each other allow movement of the deflectorpanel between at least the deployed and stowed positions.
 2. The activefront deflector assembly of claim 1, wherein the deflector panel issemi-rigid with a rigid upper spine, to absorb impact energy.
 3. Theactive front deflector assembly of claim 2, wherein when in the deployedposition during vehicle movement the rigid upper spine is not in the airflow.
 4. The active front deflector assembly of claim 1, wherein theactuator correlates with vehicle communication networks for commandingoperation of the actuator based upon predetermined conditions.
 5. Theactive front deflector assembly of claim 4, wherein the predeterminedconditions are selected from the group consisting of vehicle speed, winddirection, yaw, and combinations thereof.
 6. The active front deflectorassembly of claim 5, wherein the predetermined condition for deployingthe deflector panel is vehicle speed in the range of at least 30 milesper hour.
 7. The active front deflector assembly of claim 1, wherein thepredetermined condition for retracting the deflector panel is vehiclespeed in the range of less than 30 miles per hour.
 8. The active frontdeflector assembly of claim 1, further comprising a plurality ofattachment brackets to attach the at least two linkage assemblies towardthe front of the vehicle.
 9. The active front deflector assembly ofclaim 1, wherein the at least two linkage assemblies each furthercomprise: a coupler link, where the coupler link is attached to an upperspine that is rigid of the deflector panel; a fixed base link, where thefixed base link is attached to the vehicle; a drive link pivotablyconnected to the coupler link and fixed base link; and a follower linkpivotably connected to the coupler link and fixed base link.
 10. Theactive front deflector assembly of claim 9, wherein, when in thedeployed position, the angle between the fixed base link and drive linkin the deployed position is 76 degrees.
 11. The active front deflectorassembly of claim 9, wherein, when the at least two linkage assembliesare in the retracted position, the angle between the fixed base link andthe follower link is 66 degrees.
 12. The active front deflector assemblyof claim 11, where a first pair of opposing sides of the at least twolinkage assemblies are equal in length and parallel and a second pair ofopposing sides of the at least two linkage assemblies are equal inlength and parallel, where the lengths of the first and second pairs arenot the same.
 13. The active front deflector assembly of claim 9,wherein the actuator is operably connected to the drive shaft which isattached to the drive links and fixed base links of the at least twolinkage assemblies, where rotation of the drive shaft rotates the drivelinks upward causing the follower and coupler links to fold upwardcausing the deflector panel to rise out of the air flow to the retractedposition, and wherein rotation of the drive shaft in the oppositedirection rotates the drive links downward causing the follower andcoupler links down and the deflector panel to lower into the air flow tothe deployed position.
 14. The active front deflector assembly of claim9, wherein each coupler link has the mounting portion that is L-shapedwith an upper portion attached to the top surface of a rigid upper spineportion of the deflector panel with at least two fasteners.
 15. Theactive front deflector assembly of claim 1, further comprising at leastone attachment bracket connected to each of the linkage assemblies,wherein the attachment brackets connect the active front assembly to thevehicle using at least one fastener.
 16. An active front deflectorassembly for a motor vehicle, comprising: at least one deflector panelincluding a semi-rigid portion and a rigid upper spine portion, wherethe deflector panel selectively deploys and retracts between a deployedposition within an air flow, a stowed position out of the air flow, andpredetermined partially deployed positions therebetween, where thedeployment and partial deployment of the deflector panel improvesaerodynamics; at least two linkage assemblies attached to the rigidupper spine of the deflector panel and connected to the vehicle, eachlinkage assembly forming only a parallelogram shape when in the deployedposition and when in the retracted position, wherein the angle between afixed base link and a drive link of each of said at least two linkageassemblies is about 66 to 76 degrees; and an actuator; a drive shaftoperably coupled to the actuator and to the at least two linkageassemblies, where the actuator is in communication with the vehicle andautomatically deploys the deployable panel under predeterminedconditions and automatically retracts the deployable panel whenpredetermined conditions for continued deployment are no longer met;wherein the predetermined conditions are selected from the groupconsisting of vehicle speeds, wind directions, yaw, and combinationsthereof, and wherein the parallelogram geometry and a ratio of the linksto each other allow movement of the deflector panel between at least thedeployed and retracted positions.
 17. The active front deflectorassembly of claim 16, wherein the at least two linkage assemblies eachfurther comprise: a coupler link, where the coupler link is attached tothe upper spine of the deflector panel; the fixed base link, where thefixed base link is adapted to the vehicle; the drive link pivotablyconnected to the coupler link and fixed base link; and a follower linkpivotably connected to the coupler link and fixed base link.
 18. Theactive front deflector assembly of claim 17, wherein, when in thedeployed position, the angle between the fixed base link and drive linkin the deployed position is 76 degrees, and, when the at least twolinkage assemblies are in the retracted position, the angle between thefixed base link and the follower link is 66 degrees.
 19. The activefront deflector assembly of claim 18, where a first pair of opposingsides of the at least two linkage assemblies are equal in length andparallel and a second pair of opposing sides of the at least two linkageassemblies are equal in length and parallel, where the lengths of thefirst and second pairs are not the same.